CHAPTER 2

MEDIUM VOLTAGE POWER LINE DESIGN AND

CONSTRUCTION
2.1 Selection of Line Route and Profile Survey

Medium voltage (33 kV) power line design and construction in Sri Lanka is done by
Projects and Heavy Maintenance branches of four Distribution Regions (Distribution
Licensees) of Ceylon Electricity Board. Distribution planning branches of four
distribution licensees decide new power line requirement and the features of decided
lines. Starting grid substations and ending switching gantry points are identified for
planned medium voltage backbone lines.

After selection of start and end points of the line, next step is to identify and mark the
line route on 1:50,000 maps. In this stage, main consideration is given to select
paddy fields for the line route as much as possible in accordance with availability,
and to avoid highly populated areas, sanctuaries, reserved forests, schools, religious
premises and places of historical importance. The next consideration is for avoiding
marshy lands where access is difficult and which incur high foundation costs.
Considering above facts the possible line route is marked roughly on 1:50,000 map
from grid substation to the proposed gantry.

Next step is to conduct field visits to confirm the route marked on the map. During
field visits, the places are identified where some marks on the map have been
developed or differed. To encounter with these changes found in the field, previous
line route selected should be adjusted shifting existing angle points or introducing
new angle points. Finally a feasible preliminary line route is selected and next step is
to start the preliminary survey along the selected line route.

Preliminary survey of the line route is carried out by licensed surveyors. Surveyor
produces a preliminary drawing of the plan view and profile view through selected
line route in 1:2000 horizontal scales. Details and information included in the
preliminary drawings are [7],

10
  The visual nature of the ground within 60m band of 30m to each side of the
center line.

 All buildings and high obstructions (with their height) within 60m band of 30m
to each side of the center line.

 Voltage, height of lower, upper conductor and earth wire of all power lines
within the 60m band of 30m to each side of the center line.

 Details of all telecommunication lines within 60m band of 30m to each side of
the center line.

 Details of all roads, pathways, rivers, canals and drains (with their widths)
within 60m band of 30m to each side of the center line.

 Angle of deviation of the line including sketch of tie measurement to re-

establish any missing pegs in future.

 Valuable trees and Plants.

Detailed profile survey is carried out after studying the preliminary profile survey
and deciding the required modifications. The profile drawing is prepared with
horizontal scale of 1:2000 and a vertical scale of 1:200. Following details and
information should be included in the detailed profile drawing [7].

 The visual nature of the ground with special reference to paddy fields, marshy
soft ground or instability, paths and seismic disturbance.

 All buildings or high obstructions within 20m band of 10m to each side of the
center line.

 At each angle position a ‘tie-in’ sketch.

 All changes of levels of 300 mm or more along the route centerline and along
the offset lines. All features such as hedges, fences, ditches, roads, railways,
rivers, canals, buildings, telegraph, power and pipelines should be included.

11
  Following details at the crossings of power lines:
- Voltage and type of construction
- Ground levels at point of crossing and support structures
- Height of the top Conductor/Earth wire and lowest Conductor at point
of crossing and support structures
- Distance from crossing point to support structures along route of line
to be crossed and the angle of crossing

 Along the bottom of the profile sheet a route map plan view showing all relevant
details, within a distance of 10m each side of the route centerline should be
drawn, to the same scale as the horizontal scale of the profile.

2.2. Selection of Line Supports

Broad based lattice steel structures are used as the common support type for medium
voltage backbone lines. “Tower” and “Mast” are the two steel structures designs
adopted now in the sector. In a basic Tower type structure, the height to lowest
conductor attachment point is 14 m. Mast type steel structures are smaller in size and
lower in height compared to Tower type structures. It has only 10m to lowest
conductor attachment point. Applications of two support types are determined with
terrain features along the line route.

Lines in urban and mountainous areas

The double circuit steel support type “Tower” are used with “Aluminum Conductor
Steel Re-inforced (ACSR 30/2.79, 7/2.79) Lynx” conductor and 7/3.25 Galvanized
Steel Earth Wire, in 33 kV lines in urban and mountainous areas.

Towers are self supporting, broad based lattice steel structures, which are categories
in accordance with their ranges of bearable horizontal angles. Categorization of
33kV Towers is stated in Table 2.1. In support notation, the support type (whether
Tower or Mast) is denoted by its first letter. Middle letter represent number of
circuits which can attach to the support and last letter represent angle type. A
drawing of basic Tower type structure is attached as Appendix 1.

12
 Table 2.1: Types of Tower steel structures

Tower type symbol Description Horizontal Angle

TDL Suspension (line) tower 00
TDM Medium angle section tower 00 - 300
TDH Heavy angle section tower 300 - 600
TDT Terminal tower 00 - 450 entry on line side

Body extensions of 3m and 6m and leg extensions of -2m, -1m, 0m, +1m, +2m and
+3m are available for use in sites where required. Basic span for tower lines is 300m.

Lines in non-urban low country areas

The double circuit steel support type “Mast” is used with ACSR Lynx conductor and
7/3.25Galvanized Steel Earth Wire, for 33 kV lines in non-urban and low country
area. Types of 33 kV double circuit Masts are stated in Table 2.2.

Table 2.2: Types of Mast steel structures

Mast type symbol Description Horizontal Angle

MDL Suspension (line) mast 00
MDM Light angle section mast 00 - 300
MDH Heavy angle section mast 300 - 600
MDT Terminal mast 00- 450 entry on line side

Body extensions are available from +1m to +6m in 1m intervals for MDL and in case
of MDM, MDH and MDT, +3m and +6m body extensions are available. Basic span
for the mast lines is 200m.

Summary of the support types with their approximate height to bottom conductor
attachment point is appended in Table 2.3.The integer which is appeared after “+”
mark of support symbol represents available body extension height (e.g. TDM+3
represent double circuit medium angle tower three meter body extension). A drawing
of basic Mast type structure is attached as Appendix 2.

13
 Table 2.3: Medium voltage line support types and heights

Support Type Height to bottom conductor

TDL+0, TDM+0, TDH+0, TDT+0 14 m
Tower TDL+3, TDM+3, TDH+3, TDT+3 17 m
TDL+6, TDM+6, TDH+6, TDT+6 20 m
MDL+0, MDM+0, MDH+0, MDT+0 10 m
Mast MDL+3, MDM+3, MDH+3, MDT+3 13 m
MDL+6, MDM+6, MDH+6, MDT+6 16 m

2.3. Sag-Tension Calculation

Y
L
A B

X
O
Figure 2.1: Conductor sag curve

If conductor is sagged with a given tensile force between A and B which represents
the attachments of the conductor at the support as indicated by Figure 2.1, sagging
curve will be formed due to force balance between conductor dead loads and tensile
forces. This sagging curve is known as the catenary curve. Vertical distance of the
conductor at any point of conductor to the line connecting A and B attachment points
is called “Conductor Sag” at particular point.
Conductor catenary curve equation is;

𝑇𝑇𝐻𝐻 𝑤𝑤𝑤𝑤
𝑦𝑦 = [𝐶𝐶𝐶𝐶𝐶𝐶ℎ � � − 1] (2.1)[8]
𝑤𝑤 𝑇𝑇𝐻𝐻

Where, w = conductor unit weight and T H = Horizontal tension of conductor.

𝑤𝑤𝑤𝑤 2
Approximated Formula 𝑦𝑦 = (2.2)[8]
2𝑇𝑇𝐻𝐻

14
When span is L the maximum sag,
𝐿𝐿
𝑤𝑤(2)2
𝐷𝐷 =
2𝑇𝑇𝐻𝐻

𝑤𝑤 𝐿𝐿2
𝐷𝐷 = (2.3)
8𝑇𝑇𝐻𝐻

Conductor Basic Span

The basic span of a line or a set of structures is the span for which maximum sag has
been calculated to determine the height of standard structures. A conductor correctly
tensioned between two standard height structures, a basic span apart on flat ground
will have the minimum design ground clearance. For the two support types Tower
and Mast has different basic spans since those supports are with different basic
heights [6].

Equivalent Span

Sags and tension of a line section (between two tension supports) are calculated on
the “Constant Tension” and “Equivalent Span” principle. The theory is that any
applied tension will be constant and uniform throughout the section and this constant
tension will produce finite sag on equivalent span. Mathematical expression for
determining the equivalent span for a section made up of five spans with lengths, a,
b, c, d and e could be expressed as indicated in Equation (2.4).

𝑎𝑎 3 +𝑏𝑏 3 +𝑐𝑐 3 +𝑑𝑑 3 +𝑒𝑒 3

𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 = � (2.4) [9]
𝑎𝑎+𝑏𝑏+𝑐𝑐+𝑑𝑑+𝑒𝑒

Wind Span
The term wind span represents half the sum of adjacent horizontal span lengths
supported on any one support. To maintain the loads within support strength
limitations, wind span limits have been defined for each support type. The span for
broken wire conditions will be applied only for one phase conductor or earth wire
considered broken. The loading for intact wires will be based upon normal working
loads [9].

15
Weight Span

The term weight span represents the equivalent length of the weight of conductor
supported at any one support at minimum temperature at still air [9].

Wind span and weight span limits related to tower and mast supports are stated in
Table 2.4.

Table 2.4: Medium voltage line supports, wind span and weight span limits

Tower Type Description Wind Span(m) Weight Span(m)

Mast MDL Suspension Tower 0o < 240 < 400

o o
Double MDM Light angle section tower 0 -30 < 240 < 600
o o
MDH Heavy angle tower 30 -60 < 240 < 600
Circuit
o o
MDT Terminal tower 0 -45 entry on line side < 240 < 600
o
Tower TDL Suspension Tower 0 < 360 < 600
o o
TDM Light angle section tower 0 -30 < 360 -600 to 1200
Double
o o
TDH Heavy angle tower 30 -60 < 360 -600 to 1200
Circuit
o o
TDT Terminal tower 0 -45 entry on line side < 360 -600 to 1200
Source: CEB MV Overhead Line Design and Construction Tender Document

2.4. Conductor State Change Equation

A conductor stringed between two supports is undergone number of changes with the
change of weather and climate conditions such as temperature, wind and ice. From
above mentioned conditions, ice is not considered for power lines in Sri Lanka.
Following tension conditions should be satisfied by the conductor for conductor to be
within tensile strength limits [9],

- Tension of the conductor at the highest tension conditions (minimum

temperature with wind) should keep a safety factor of 2.5 with the Ultimate
Tensile Strength (UTS).
- At everyday conditions at no wind the safety factor should be 4.5.
- At highest temperature at no wind condition the tension should be such that the
ground clearance should not be violated.

16
Starting with one condition, calculating sag and tension at the other condition is the
procedure in sag-tension calculation of power lines. A tower line conductor is usually
subjected to following external forces:
- A horizontal force due to wind pressure.
- A vertical force due to dead weight of conductor.
If w is the weight of conductor per meter length and p is the horizontal force due to
wind pressure acting on the conductor per meter length, the resultant force q on
conductor per meter length is,

𝑞𝑞 = �(𝑤𝑤 2 + 𝑝𝑝2 ) (2.5)

Proportion of q to unit conductor weight p is called the wind factor and it is shown as
Q where,

�(𝑤𝑤 2 +𝑝𝑝 2 )
𝑄𝑄 = (2.6)
𝑤𝑤

If temperature or loading conditions varies in a span, the conductor length will be

expanded or contracted, resulting again in a variation of the conductor tensile force.
This changing of tensile force changes conductor sag curve as shown in Figure 2.2.
These changes could be calculated by “Conductor State Change Equation”; Equation
(2.7).

a
A B

State 2

State 1

Figure 2.2: Conductor state change

𝑎𝑎 2 𝛿𝛿 2 𝑄𝑄12 𝐸𝐸 𝑎𝑎 2 𝛿𝛿 2 𝑄𝑄22 𝐸𝐸
𝑓𝑓22 �𝑓𝑓2 − �𝑓𝑓1 − 24𝑓𝑓12
− 𝛼𝛼𝛼𝛼𝛼𝛼�� = 24
(2.7)[8]

17
Where,
A = Cross section area of the conductor
f 1 = H 1 /A ; H 1 = Horizontal tension at state 1 of the conductor
f 2 = H 2 /A ; H 2 = Horizontal tension at state 2 of the conductor
a = Span length AB
δ = w/A ; w = unit weight of the conductor
Q 1 = Wind factor at state 1
Q 2 = Wind factor at state 2
α = Coefficient of linear expansion of the conductor
t = t 2 -t 1 ; t 1 = Temperature at state 1, t 2 = Temperature at state 2
E = Modulus of elasticity of the conductor

2.5. Medium Voltage line design conventional procedure

In conventional method of medium voltage line design, the design engineers do

designs on hard profile drawings or Auto-CADD profile drawings, which are
provided by the surveyor. Under mentioned steps are followed by the design
engineer in the design process of medium voltage overhead power lines in
conventional method. Following abbreviations have been used in the explanation [7].

MWT - Maximum working tension of the line (i.e. at minimum temperature, 7oC,
with wind)
EDT - Every day temperature (i. e. at 32oC and no wind condition)
MOT - Maximum operating temperature (i. e. at 75oC without wind)
UTS - Ultimate tensile strength of the conductor

Step 1: Find the equivalent span of the tension section.

Step 2:

• Apply MWT as initial condition (i. e. T 1 = UTS/2.5) and find the horizontal
tension T 2 of the conductor at EDT (at 32oC) for the particular equivalent span
value.

18
• For obtained T 2 check the EDT condition (i. e. T 2 < UTS/4.5) for the equivalent
span.
• If EDT condition is not satisfied redo the calculation taking EDT (i. e. T 1 =
UTS/4.5) as the initial condition and find T 2 at minimum temperature (7 oC) with
wind condition.
Step 3: Apply MWT (output of step 1) as initial condition and find T 2 at MOT (i. e.
75 oC) for the equivalent span.

Step 4:

• Find Sag (d) at MOT using maximum sag equation,

𝑤𝑤𝑎𝑎2
𝑑𝑑 =
8𝑇𝑇2

• Find coordinates for the catenary curves applying tension (T 2 ) at MOT for
equivalent span using,
𝑤𝑤𝑥𝑥 2
𝑦𝑦 =
2𝑇𝑇2

Step 5: Plot the ctenary curve of the conductor at 75oC with no wind for all
equivalent spans.

Step 7:

• Project the hot curve (catenary at 75oC) for ground clearance value (6.1 m for
medium voltage 33 kV).
• Including these two curves prepare the sag template for equivalent span.
Drawn curves should be carved as plastic sag templates for designing on hard
profile drawings. If the design is being done on Auto-CADD profile
drawings, the design engineer has to draw catenary curves as Auto-CADD
drawings. Sag templates should be in the scale same as scale of profile
drawing.

19
Equivalent spans which sag templates are prepared is 100m, 200m, 300m and 400m.
According to the parameters of selected section of the line, equivalent span is
differed and selection of the sag template for particular line section is done as shown
in Table 2.5.

Table 2.5: Selection of sag templates [7]

Range of equivalent span (m) Sag Template (m)

76-175 100
176-275 200
276-375 300
376-475 400

Step 8:

Required
Ground
Clearance

Tower 1 Tower 2

Figure 2.3: Placing sag template on profile drawing

After preparing sag templates, the design engineer starts tower spotting on profile
drawings. Drawing of a sample sag template is shown in Figure 2.4. Tower spotting
process is carried out section wise along the line route by placing designed sag
template on hard profile drawing. After, location and height of starting tower of a
span is decided, the selected sag template for equivalent span placed on the profile
drawing as shown in Figure 2.3, to decide next tower location and height. Angle

20
points along the selected route are fixed points for tower locations. Only heights of
angle towers are to be decided at tower spotting stage.

Figure 2.4: Sample sag template

In Figure 2.3, sagging template has been placed in a position to determine the
location and height of Tower 2, assuming that Tower 1 is fixed at location 1. The
sagging curve starts at the conductor attachment point of Tower 1. Sagging template
is adjusted such that its horizontal edge is placed parallel to the horizontal line of
longitudinal profile.

After preparing preliminary tower spotting, wind and weight spans need to be
checked in detail for each tower placed. If these conditions are not complied with
tower heights; tower types or the tower spotting at all need to be corrected
accordingly.

21
2.6. Design by PLS-CADD power line design software (Manual Spotting)

PLS-CADD software is available for easily carried out the explained design steps.
Design procedure has become simplified and less time consuming with PLS-CADD
software. The files and parameters we have to input to the PLS-CADD program is,
- Profile survey data: X, Y, Z, H co-ordinates of profile survey points with
feature code as a comma-delimited Microsoft Excel work sheet.
- Feature code file (definition of available feature types)
- Design criteria file (definition of safety factors, wind and weight span limits,
weather conditions, etc.)
- Conductor file (definition of conductor parameters)
- Structure files (definitions of structure parameters of each structure type)
Then, profile view and plan view of terrain is developed by the software as shown in
Figure 2.5.

Figure 2.5: Profile terrain; profile view and plan view

PLS-CADD software does not have inbuilt procedure for automatic tower spotting.
The procedure is available as extra cost optional facility. Therefore, in basic PLS-
CADD software interface, the Design Engineer has to spot structures manually along
the developed profile view. If any design constraint is violated (eg: wind or weight

22
span limits, required clearances, etc.), the Design Engineer has to correct it by
shifting structure locations or changing the tower heights manually. By this way the
final design of the line by PLS-CADD software is also achieved by the trial and error
method.

2.7. Importance of Medium Voltage Power line cost optimization

Figure 2.6 and Figure 2.7 shows two manually spotted designs of a section of 33 kV
Lynx double circuit tower line from Polonnaruwa Grid Substation to 33 kV Gantry at
Jayanthipura. In the figures, two possible design configurations have been shown for
the same line section in manual spotting. Section length is 1958 m and section
starting and end towers are medium angle towers.

Figure 2.6: Design solution 1 for a line section of MV line

Figure 2.7: Design solution 2 for a line section of MV line

In first solution, the design was done placing five suspension towers in between two
medium angle towers with different body extensions. In second solution, six
suspension towers were placed without body extensions. Comparison of two

23
solutions is shown in Table 2.6 with their estimated construction costs. The total
construction cost of each tower type which is used for cost calculation, is shown in
Table 2.7. The comparison shows that, solution 2 incurred 4.8% higher cost than the
solution 1.
Table 2.6: Cost comparison of two design solutions
Solution Tower Configuration Total Cost (LKR)
No.
TDM+0, TDL+3, TDL+0, TDL+3, TDL+0,
1 7,502,096.00
TDL+6, TDM+0
TDM+0, TDL+0, TDL+0, TDL+0, TDL+0,
2 7,899,932.00
TDL+0, TDL+0, TDM+0
Cost difference 357,836.00

Table 2.7: Total cost of tower steel parts, erection and foundation
Tower Cost + Erection and
Tower type
Foundation Cost (Good Soil) (LKR)
TDL TDL+0 815,518
TDL+3 939,990
TDL+6 1,024,250
TDM TDM+0 1,483,412
TDM+3 1,656,245
TDM+6 1,804,382
TDH TDH+0 1,568,573
TDH+3 1,797,392
TDH+6 1,933,763
TDT TDT+0 1,477,373
TDT+3 1,977,648
TDT+6 2,142,983
Source: CEB stock values-2012

Each section of line has many design solutions which incur different investments
from each other. The design engineer is hardly in a position to manually identify and
evaluate all the solutions available for a line section. Therefore, application of
automatic design methodology with cost optimization is highly valuable for
reduction of investment at initial stage.

24